Rosemount 4081FG 2-Wire In Situ O2 Analyzer (550° to 1600°C) Owner's manual

Instruction Manual

IB-106-4081 Rev. 1.2

September, 2002

http://www.processanalytic.com

Model 4081FG

Two-Wire In Situ Oxygen Analyzer

(550° to 1600°C) with F

OUNDATION

Fieldbus Communications

Emerson Process Management

Rosemount Analytical Inc.

Process Analytic Division

1201 N. Main St.

Orrville, OH 44667-0901

T (330) 682-9010

F (330) 684-4434

e-mail: [email protected]om

http://www.processanalytic.com

ESSENTIAL INSTRUCTIONS

READ THIS PAGE BEFORE PROCEEDING!

Rosemount Analytical designs, manufactures and tests its products to meet many national and

international standards. Because these instruments are sophisticated technical products, you

MUST properly install, use, and maintain them to ensure they continue to operate within their

normal specifications. The following instructions MUST be adhered to and integrated into your

safety program when installing, using, and maintaining Rosemount Analytical products. Failure to

follow the proper instructions may cause any one of the following situations to occur: Loss of life;

personal injury; property damage; damage to this instrument; and warranty invalidation.

• Read all instructions prior to installing, operating, and servicing the product.

• If you do not understand any of the instructions, contact your Rosemount Analytical repre-

sentative for clarification.

• Follow all warnings, cautions, and instructions marked on and supplied with the product.

• Inform and educate your personnel in the proper installation, operation, and mainte-

nance of the product.

• Install your equipment as specified in the Installation Instructions of the appropriate In-

struction Manual and per applicable local and national codes. Connect all products to the

proper electrical and pressure sources.

• To ensure proper performance, use qualified personnel to install, operate, update, program,

and maintain the product.

• When replacement parts are required, ensure that qualified people use replacement parts

specified by Rosemount. Unauthorized parts and procedures can affect the product’s per-

formance, place the safe operation of your process at risk, and VOID YOUR WARRANTY.

Look-alike substitutions may result in fire, electrical hazards, or improper operation.

• Ensure that all equipment doors are closed and protective covers are in place, except

when maintenance is being performed by qualified persons, to prevent electrical shock

and personal injury.

The information contained in this document is subject to change without notice.

HIGHLIGHTS OF CHANGES

Effective April, 2001 Rev. 1.0

Page Summary

Throughout Changed all references of 38 in. (965 mm) probe to 34.625 in. (880 mm).

Page 11-2 Added drawing 1400175.

Effective December, 2001 Rev. 1.1

Page Summary

Page 1-3 Updated Product Matrix.

Effective September, 2002 Rev. 1.2

Page Summary

Page 1-8 Updated process temperature limits specification.

Instruction Manual

IB-106-4081 Rev. 1.2

September, 2002

Rosemount Analytical Inc. A Division of Emerson Process Management i

Model 4081FG

TABLE OF CONTENTS

PREFACE........................................................................................................................ P-1

Definitions ........................................................................................................................ P-1

Safety Instructions .......................................................................................................... P-2

1-0 DESCRIPTION AND SPECIFICATIONS........................................................................ 1-1

1-1 Component Checklist of Typical System (Package Contents).................................. 1-1

1-2 System Overview............................................................................................................ 1-1

1-3 Specifications................................................................................................................... 1-8

2-0 INSTALLATION .............................................................................................................. 2-1

2-1 Pre-Installation................................................................................................................. 2-1

2-2 Mechanical Installation ................................................................................................... 2-1

2-3 Electrical Installation.....................................................................................................2-10

2-4 Pneumatic Installation .................................................................................................. 2-11

3-0 STARTUP........................................................................................................................ 3-1

3-1 General ............................................................................................................................ 3-1

3-2 Power Up........................................................................................................................ 3-1

3-3 Reestablishing Proper Calibration Check Gas Flow Rate......................................... 3-2

4-0 OPERATION ...................................................................................................................4-1

4-1 General ............................................................................................................................ 4-1

4-2 Program Menu ................................................................................................................4-4

4-3 Diagnostics Menu ........................................................................................................... 4-8

4-4 CALCHECK MENU ...................................................................................................... 4-12

4-5 SIMULATE SWITCH .................................................................................................... 4-15

4-6 SECURITY SWITCH .................................................................................................... 4-15

5-0 MAINTENANCE AND SERVICE .................................................................................. 5-1

5-1 MODEL 4081 ELECTRONICS REPLACEMENT ........................................................... 5-1

5-2 OXYGEN PROBE REPLACEMENT ............................................................................. 5-2

6-0 TROUBLESHOOTING .................................................................................................... 6-1

6-1 GENERAL........................................................................................................................ 6-1

6-2 PROBE LIFE.................................................................................................................... 6-1

6-3 FAULT INDICATIONS .................................................................................................... 6-2

6-4 IDENTIFYING AND CORRECTING FAULT INDICATIONS ....................................... 6-3

7-0 RETURN OF MATERIAL .............................................................................................. 7-1

8-0 REPLACEMENT PARTS ............................................................................................... 8-1

9-0 APPENDICES ................................................................................................................. 9-1

10-0 INDEX............................................................................................................................ 10-1

11-0 DRAWINGS AND SCHEMATICS ............................................................................... 11-1

Instruction Manual

IB-106-4081 Rev. 1.2

September, 2002

ii Rosemount Analytical Inc. A Division of Emerson Process Management

Model 4081FG

LIST OF ILLUSTRATIONS

Figure 1-1. Typical System Package ....................................................................................... 1-2

Figure 1-2. Two-Wire In Situ Oxygen Analyzer Fieldbus Connections.................................... 1-7

Figure 1-3. Typical System Installation .................................................................................... 1-7

Figure 2-1. Probe Installation Details ....................................................................................... 2-2

Figure 2-2. Optional Adapter Plate........................................................................................... 2-2

Figure 2-3. Optional Probe Mounting Flange ........................................................................... 2-3

Figure 2-4. Horizontal Probe Installation.................................................................................. 2-4

Figure 2-5. Adjusting Probe Insertion Depth ............................................................................ 2-5

Figure 2-6. Flat Surface Mounting Dimensional Information.................................................... 2-7

Figure 2-7. Pipe Mounting Dimensional Information................................................................ 2-8

Figure 2-8. Display Positioning Assembly................................................................................ 2-9

Figure 2-9. Oxygen Probe Terminal Block ............................................................................. 2-11

Figure 2-10. Model 4081 Transmitter Terminal Block.............................................................. 2-11

Figure 2-11. Oxygen Probe Gas Connections ......................................................................... 2-12

Figure 2-12. Air Set, Plant Air Connection ............................................................................... 2-12

Figure 3-1. Normal Operation Display...................................................................................... 3-1

Figure 3-2. Faulted Operation Display ..................................................................................... 3-1

Figure 3-3. Proper Calibration Check Gas Flow Rate.............................................................. 3-2

Figure 4-1. Normal Operation Display...................................................................................... 4-1

Figure 4-2. Model 4081 Transmitter Menu Tree ...................................................................... 4-2

Figure 4-3. Infrared Remote Control (IRC)............................................................................... 4-3

Figure 4-4. CODE..................................................................................................................... 4-4

Figure 4-5. DISPLAY CODE ................................................................................................... 4-5

Figure 4-6. CELL T HI ............................................................................................................ 4-5

Figure 4-7. RESET MAX CELL T.......................................................................................... 4-6

Figure 4-8. SET O

2

FILTER TIME......................................................................................... 4-6

Figure 4-9. SET HI BOTTLE O

2

............................................................................................ 4-7

Figure 4-10. SET LO BOTTLE O

2

........................................................................................... 4-7

Figure 4-11. SET CODE............................................................................................................ 4-8

Figure 4-12. SHOW FAULT ...................................................................................................... 4-8

Figure 4-13. T/C mV................................................................................................................... 4-9

Figure 4-14. O

2

CELL mV ........................................................................................................ 4-9

Figure 4-15. CELL IMPEDANCE............................................................................................. 4-10

Figure 4-16. PREVIOUS SLOPE ............................................................................................ 4-10

Figure 4-17. PREVIOUS CONSTANT .................................................................................... 4-11

Figure 4-18. MAX CELL T...................................................................................................... 4-11

Figure 4-19. IN MANUAL? ...................................................................................................... 4-12

Figure 4-20. ACCEPT HIGH O

2

............................................................................................. 4-13

Figure 4-21. ACCEPT LOW O

2

.............................................................................................. 4-13

Figure 4-22. PURGING ............................................................................................................ 4-14

Figure 4-23. SLOPE ................................................................................................................. 4-14

Figure 4-24. CONSTANT ......................................................................................................... 4-14

Figure 4-25. Simulate and Security Switch Positions .............................................................. 4-15

Figure 5-1. Two-Wire In Situ Oxygen Analyzer Exploded View............................................... 5-0

Figure 5-2. Oxygen Probe Terminal Block ............................................................................... 5-3

Figure 6-1. Slope vs. Impedance ............................................................................................. 6-1

Figure 6-2. Speed of Response ............................................................................................... 6-2

Figure 6-3. Faulted Operation Display ..................................................................................... 6-2

Figure 6-4. Model 4081 Transmitter Terminal Block ................................................................ 6-3

Figure 6-5. Fault 1, Open Thermocouple ................................................................................. 6-4

Instruction Manual

IB-106-4081 Rev. 1.2

September, 2002

Rosemount Analytical Inc. A Division of Emerson Process Management iii

Model 4081FG

LIST OF ILLUSTRATIONS (CONTINUED)

Figure 6-6. Fault 2, Reversed Thermocouple .......................................................................... 6-4

Figure 6-7. Fault 3, Shorted Thermocouple ............................................................................. 6-5

Figure 6-8. Fault 4, High Probe Temperature .......................................................................... 6-5

Figure 6-9. Fault 5, O

2

Cell Open............................................................................................. 6-6

Figure 6-10. Fault 6, Cell Impedance Too High ......................................................................... 6-6

Figure 6-11. Fault 7, Reversed O

2

Cell ...................................................................................... 6-7

LIST OF TABLES

Table 1-1. Product Matrix........................................................................................................ 1-3

Table 1-2. Accessories............................................................................................................ 1-4

Table 1-3. Mounting Adapter................................................................................................... 1-4

Table 4-1. Model 4081 Transmitter Parameters ..................................................................... 4-8

Table 8-1. Replacement Parts List.......................................................................................... 8-1

Instruction Manual

IB-106-4081 Rev. 1.2

September, 2002

iv Rosemount Analytical Inc. A Division of Emerson Process Management

Model 4081FG

Instruction Manual

IB-106-4081 Rev. 1.2

September, 2002

Rosemount Analytical Inc. A Division of Emerson Process Management P-1

Model 4081FG

PREFACE

The purpose of this manual is to provide information concerning the components, func-

tions, installation and maintenance of this particular NGA 2000 module.

Some sections may describe equipment not used in your configuration. The user should

become thoroughly familiar with the operation of this module before operating it. Read

this instruction manual completely.

DEFINITIONS

The following definitions apply to WARNINGS, CAUTIONS, and NOTES found throughout this

publication.

Highlights an operation or maintenance

procedure, practice, condition, state-

ment, etc. If not strictly observed, could

result in injury, death, or long-term

health hazards of personnel.

Highlights an operation or maintenance

procedure, practice, condition, state-

ment, etc. If not strictly observed, could

result in damage to or destruction of

equipment, or loss of effectiveness.

NOTE

Highlights an essential operating procedure,

condition, or statement.

: EARTH (GROUND) TERMINAL

: PROTECTIVE CONDUCTOR TERMINAL

: RISK OF ELECTRICAL SHOCK

: WARNING: REFER TO INSTRUCTION BULLETIN

NOTE TO USERS

The number in the lower right corner of each illustration in this publication is a manual illus-

tration number. It is not a part number, and is not related to the illustration in any technical

manner.

Instruction Manual

IB-106-4081 Rev. 1.2

September, 2002

P-2 Rosemount Analytical Inc. A Division of Emerson Process Management

Model 4081FG

IMPORTANT

SAFETY INSTRUCTIONS

FOR THE WIRING AND INSTALLATION

OF THIS APPARATUS

The following safety instructions apply specifically to all EU member states. They should

be strictly adhered to in order to assure compliance with the Low Voltage Directive. Non-

EU states should also comply with the following unless superseded by local or National

Standards.

1. Adequate earth connections should be made to all earthing points, internal and external,

where provided.

2. After installation or troubleshooting, all safety covers and safety grounds must be replaced.

The integrity of all earth terminals must be maintained at all times.

3. Mains supply cords should comply with the requirements of IEC227 or IEC245.

4. All wiring shall be suitable for use in an ambient temperature of greater than 75°C.

5. All cable glands used should be of such internal dimensions as to provide adequate cable

anchorage.

6. To ensure safe operation of this equipment, connection to the mains supply should only be

made through a circuit breaker which will disconnect all circuits carrying conductors during a

fault situation. The circuit breaker may also include a mechanically operated isolating switch.

If not, then another means of disconnecting the equipment from the supply must be provided

and clearly marked as such. Circuit breakers or switches must comply with a recognized

standard such as IEC947. All wiring must conform with any local standards.

7. Where equipment or covers are marked with the symbol to the right, hazard-

ous voltages are likely to be present beneath. These covers should only be

removed when power is removed from the equipment — and then only by

trained service personnel.

8. Where equipment or covers are marked with the symbol to the right, there is a

danger from hot surfaces beneath. These covers should only be removed by

trained service personnel when power is removed from the equipment. Cer-

tain surfaces may remain hot to the touch.

9. Where equipment or covers are marked with the symbol to the right, refer to

the Operator Manual for instructions.

10. All graphical symbols used in this product are from one or more of the follow-

ing standards: EN61010-1, IEC417, and ISO3864.

Instruction Manual

IB-106-4081 Rev. 1.2

September, 2002

Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-1

Model 4081FG

SECTION 1

DESCRIPTION AND SPECIFICATIONS

1-1 COMPONENT CHECKLIST OF TYPICAL

SYSTEM (PACKAGE CONTENTS)

A typical Rosemount Two-Wire In Situ Oxygen

Analyzer should contain the items shown in

Figure 1-1. Record the part number, serial num-

ber, and order number for each component of

your system in the table located on the first

page of this manual. Also, use the product ma-

trix in Table 1-1 to compare your order number

against your unit. The first part of the matrix de-

fines the model. The last part defines the vari-

ous options and features of the analyzer.

Ensure the features and options specified by

your order number are on or included with the

unit.

1-2 SYSTEM OVERVIEW

a. Scope

This Instruction Bulletin is designed to sup-

ply details needed to install, start up, oper-

ate, and maintain the Rosemount Two-Wire

In Situ Oxygen Analyzer. The analyzer con-

sists of an oxygen probe and Model 4081

Transmitter. Integral signal conditioning

electronics outputs a digital F

OUNDATION

fieldbus signal representing an O

2

value. An

infrared remote control (IRC) allows access

to setup, calibration, and diagnostics. This

same information, plus additional details,

can be accessed via fieldbus digital

communications.

b. F

OUNDATION

Fieldbus Technology

FOUNDATION fieldbus is an all digital, se-

rial, two-way communication system that

inter-connects field equipment such as sen-

sors, actuators, and controllers. Fieldbus is

a Local Area Network (LAN) for instruments

used in both process and manufacturing

automation with built-in capacity to distrib-

ute the control application across the net-

work. The fieldbus environment is the base

level group of digital networks in the hierar-

chy of planet networks.

The fieldbus retains the desirable features

of the 4-20 mA analog system, including a

standardized physical interface to the wire,

bus powered devices on a single wire, and

intrinsic safety options, and enables addi-

tional capabilities, such as:

• Increased capabilities due to full digital

communications

• Reduced wiring and wire terminations

due to multiple devices on one set of

wires

• Increased selection of suppliers due to

inter-operability

• Reduced loading on control room

equipment with the distribution of some

control and input/output functions to field

devices

• Speed options for process control and

manufacturing applications

1

Instruction Manual

IB-106-4081 Rev. 1.2

September, 2002

1-2 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management

Model 4081FG

29760001

4

5

6

7

1

2

3

1. Instruction Bulletin

2. Model 4081 Transmitter

3. Oxygen Probe

4. Adapter Plate with Mounting Hardware

and Gasket (Optional)

5. Infrared Remote Control (IRC) (Optional)

6. Reference Air Set (Optional)

7. Pipe Mounting Kit (Optional)

Figure 1-1. Typical System Package

Instruction Manual

IB-106-4081 Rev. 1.2

September, 2002

Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-3

Model 4081FG

Table 1-1. Product Matrix

4081FG Model 4081FG In Situ Oxygen Analyzer with FOUNDATION Fieldbus Communications

Model 4081FG Oxygen Analyzer - Instruction Book

Code Sensing Probe Length

1 20 in. (508 mm) probe, 1/4 in. tube fittings

2 26 in. (660 mm) probe, 1/4 in. tube fittings

3 38 in. (965 mm) probe, 1/4 in. tube fittings

Code Probe Outer Tube Material - Maximum Operating Temperature

1 Alumina - 2912°F (1600°C) maximum - 1.25 NPT mounting

2 Inconel 600 - 1832°F (1000°C) maximum - 1.25 NPT mounting

Code Mounting Adapter - Stack Side

0 No adapter plate required uses 1.25 NPT (“0” must also be chosen under “Mounting Adapter” probe side)

1 New flanged installation - Square weld plate with studs (matches “Mounting Adapter” probe side)

2 Model 450 mounting (“4” must also be chosen under “Mounting Adapter” probe side)

3 Competitor's Mount (“5” must also be chosen under “Mounting Adapter” probe side)

Code Mounting Adapter - Probe Side

0 No adapter plate

1 ANSI 2 in. 150 lb flange to 1.25 NPT adapter

(6 in. dia. Flange, 4.75 in. BC with 4 x 0.75 in. dia. holes)

2 DIN to 1.25 NPT adapter (184 mm flange, 145 mm BC with 4 x 18 mm dia. holes)

3 JIS to 1.25 NPT adapter (155 mm flange, 130 mm BC with 4 x 13 mm dia. holes)

4 Model 450 to 1.25 NPT adapter

5 Competitor’s mounting flange

Code Electronics & Housing - Intrinsically Safe, NEMA 4X, IP65

1 4081 F

OUNDATION

Fieldbus Electronics - CENELEC EEx ia IIC T5 with Control Suite

2 4081 F

OUNDATION

Fieldbus Electronics - CSA pending, with Control Suite

3

4081 F

OUNDATION

Fieldbus Electronics-FM Class I, Div. I, Groups B,C,D with Control

Suite

4 4081 F

OUNDATION

Fieldbus Electronics - CENELEC EEx ia IIC T5 without Control Suite

5 4081 F

OUNDATION

Fieldbus Electronics - CSA pending, without Control Suite

6

4081 F

OUNDATION

Fieldbus Electronics-FM Class I, Div. I, Groups B,C,D without

Control Suite

Code Housing Mounting

0 Surface or wall mounting

1 1/2 to 2 in. pipe mounting

Code Communications

0 No remote control

1 Infrared Remote Control (IRC) (LCD display through cover)

Code Calibration Accessories

1 No hardware

2 Reference air flowmeters and pressure regulator

Code Armored Cable Length

00 No cable

11 20 ft (6 m)

12 40 ft (12 m)

13 60 ft (18 m)

14 80 ft (24 m)

15 100 ft (30 m)

16 150 ft (45 m)

17 200 ft (61 m)

18 300 ft (91 m)

19 400 ft (122 m)

20 500 ft (152 m)

4081FG2100111211 Example

1

Instruction Manual

IB-106-4081 Rev. 1.2

September, 2002

1-4 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management

Model 4081FG

Table 1-2. Accessories

Part No. Description

1A99135H01 Armored cable, bulk, uncut, no connectors 100’ minimum.

1A99135H02 Unarmored cable, bulk, uncut, no connectors 100’ minimum.

Order as separate items.

Table 1-3. Mounting Adapter

Type Description

Plate with studs Bolt circle diameter, number and arrangement of studs, stud thread, stud height

above mounting plate.

Plate without studs Bolt circle diameter, number and arrangement of holes, thread, depth of stud

mounting plate with accessories.

Where possible specify SPS number; otherwise provide details of the existing mounting plate.

c. System Description

The Rosemount Two-Wire In Situ Oxygen

Analyzer is designed to measure the net

concentration of oxygen in an industrial pro-

cess; i.e., the oxygen remaining after all fu-

els have been oxidized. The oxygen probe

is permanently positioned within an exhaust

duct or stack and performs its task without

the use of a sampling system. The Model

4081 Transmitter is mounted remotely and

conditions the oxygen probe outputs.

The equipment measures oxygen percent-

age by reading the voltage developed

across an electrochemical cell, which con-

sists of a small yttria-stabilized, zirconia

disc. Both sides of the disc are coated with

porous metal electrodes. The millivolt output

voltage of the cell is given by the following

Nernst equation:

EMF = KT log

10

(P

1

/P

2

) + C

Where:

1. P

2

is the partial pressure of the oxygen

in the measured gas on one side of the

cell.

2. P

1

is the partial pressure of the oxygen

in the reference air on the opposite side

of the cell.

3. T is the absolute temperature.

4. C is the cell constant.

5. K is an arithmetic constant.

NOTE

For best results, use clean, dry, in-

strument air (20.95% oxygen) as the

reference air.

NOTE

The probe uses a Type B thermocou-

ple to measure the cell temperature.

When the cell is at 550°C to 1600°C

(1022°F to 2912°F) and there are unequal

oxygen concentrations across the cell, oxy-

gen ions will travel from the high oxygen

partial pressure side to the low oxygen par-

tial pressure side of the cell. The resulting

logarithmic output voltage is approximately

50 mV per decade.

The output is proportional to the inverse

logarithm of the oxygen concentration.

Therefore, the output signal increases as

the oxygen concentration of the sample gas

decreases. This characteristic enables the

Rosemount Two-Wire In Situ Oxygen Ana-

lyzer to provide exceptional sensitivity and

accuracy at low oxygen concentrations.

Instruction Manual

IB-106-4081 Rev. 1.2

September, 2002

Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-5

Model 4081FG

Oxygen analyzer equipment measures net

oxygen concentration in the presence of all

the products of combustion, including water

vapor. Therefore, it may be considered an

analysis on a “wet” basis. In comparison

with older methods, such as the portable

apparatus, which provides an analysis on a

“dry” gas basis, the “wet” analysis will, in

general, indicate a lower percentage of

oxygen. The difference will be proportional

to the water content of the sampled gas

stream.

d. System Configuration

The equipment discussed in this manual

consists of two major components: the oxy-

gen probe and the Model 4081 Transmitter.

Oxygen probes are available in three length

options, providing in situ penetration appro-

priate to the size of the stack or duct. The

options on length are 20 in. (508 mm), 26

in. (660 mm), or 38 in. (965 mm).

The Model 4081 Transmitter is a two-wire

transmitter providing an output proportional

to the measured oxygen concentration. A

customer-supplied 24 VDC power source is

required to provide power to the electronics.

The transmitter accepts millivolt signals

generated by the probe and produces the

outputs to be used by other remotely con-

nected devices. The output is a FOUNDA-

TION fieldbus digital communication signal.

e. System Features

1. The cell output voltage and sensitivity

increase as the oxygen concentration

decreases.

2. High process temperatures eliminate

the need for external cell heating and

increase cell accuracy.

3. FOUNDATION fieldbus is standard.

4. Easy probe replacement due to the

lightweight, compact probe design.

5. Remote location of the Model 4081

Transmitter removes the electronics

from high temperature or corrosive

environments.

6. Power is supplied to the electronics

through the FOUNDATION fieldbus

digital signal line for intrinsic safety (IS)

purposes.

7. Infrared remote control (IRC) allows

inter-facing without exposing the

electronics.

8. An operator can operate and diagnos-

tically troubleshoot the Two-Wire In

Situ Oxygen Analyzer in one of two

ways:

(a) Infrared Remote Control. The IRC

allows access to fault indication

menus on the Model 4081 Trans-

mitter LCD display. Calibration can

be performed from the IRC key-

pad.

(b) FOUNDATION fieldbus Interface.

The transmitter’s output carries a

signal containing the oxygen level

encoded in digital format. This

digital output can also be used to

communicate with the oxygen

analyzer and access all of the oxy-

gen analyzer status information.

9. Selected Distributed Control Systems -

The use of distributed control systems

requires input/output (I/O) hardware

and AMS Security codes are provided

(by infrared remote control) to prevent

unintended changes to analyzers adja-

cent to the one being accessed.

10. A calibration check procedure is pro-

vided to determine if the Rosemount

Two-Wire In Situ Oxygen Analyzer is

correctly measuring the net oxygen

concentration in the industrial process.

1

Instruction Manual

IB-106-4081 Rev. 1.2

September, 2002

1-6 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management

Model 4081FG

f. Handling the Analyzer

The probe was specially packaged to pre-

vent breakage due to handling. Do not re-

move the padding material from the probe

until immediately before installation.

It is important that printed circuit

boards and integrated circuits are

handled only when adequate antistatic

precautions have been taken to pre-

vent possible equipment damage.

The oxygen probe is designed for in-

dustrial applications. Treat with care

to avoid physical damage. The probe

contains components made from ce-

ramic, which are susceptible to shock

when mishandled. THE WARRANTY

DOES NOT COVER DAMAGE FROM

MISHANDLING.

g. System Considerations

Prior to installing your Rosemount Two-Wire

In Situ Oxygen Analyzer, make sure you

have all the components necessary to make

the system installation. Ensure all the com-

ponents are properly integrated to make the

system functional.

After verifying that you have all the compo-

nents, select mounting locations and deter-

mine how each component will be placed in

terms of available line voltage, ambient

temperatures, environmental considera-

tions, convenience, and serviceability

Figure 1-2 shows the FOUNDATION Field-

bus communications interface. A typical

system installation is illustrated in Figure

1-3.

A source of instrument air is required at the

oxygen probe for reference air use. Since

the Two-Wire In Situ Oxygen Analyzer is

equipped with an in-place calibration fea-

ture, provisions should be made for con-

necting calibration check gas tanks to the

oxygen probe during calibration.

If the calibration check gas bottles are to be

permanently connected, a check valve is

required next to the calibration fittings on

the integral electronics.

This check valve is to prevent breathing of

calibration check gas line and subsequent

flue gas condensation and corrosion. The

check valve is in addition to the stop valve

in the calibration check gas kit.

NOTE

The electronics of the Model 4081

Transmitter is rated NEMA 4X (IP65)

and is capable of operating at tem-

peratures up to 65°C (149°F).

NOTE

Retain the packaging in which the

Rosemount Two-Wire In Situ Oxygen

Analyzer arrived from the factory in

case any components are to be

shipped to another site. This packag-

ing has been designed to protect the

product.

Instruction Manual

IB-106-4081 Rev. 1.2

September, 2002

Rosemount Analytical Inc. A Division of Emerson Process Management Description and Specifications 1-7

Model 4081FG

TWO-WIRE IN SITU

OXYGEN ANALYZER

INTRINSIC

SAFETY

BARRIER

(OPTIONAL)

29760002

FIELDBUS

COMPUTER TERMINAL

FIELDBUS

DIGITAL OUTPUT

(TWISTED PAIR)

MODEL 4081

TRANSMITTER

OmV

SIGNAL

2

TEMPERATURE

mV SIGNAL

REFERENCE

AIR LINE

CALIBRATION CHECK

GAS LINE

Figure 1-2. Two-Wire In Situ Oxygen Analyzer Fieldbus Connections

DUCT

STACK

GASES

PRESSURE

REGULATOR

FLOWMETER

OPTIONAL

ADAPTER

PLATE

FIELDBUS

DIGITAL SIGNAL

29760003

MODEL 4081

TRANSMITTER

OXYGEN

PROBE

INSTRUMENT

AIR SUPPLY

(REFERENCE AIR)

Figure 1-3. Typical System Installation

1

Instruction Manual

IB-106-4081 Rev. 1.2

September, 2002

1-8 Description and Specifications Rosemount Analytical Inc. A Division of Emerson Process Management

Model 4081FG

1-3 SPECIFICATIONS

Net O

2

Range ...................................................... 0 to 25% O

2

Fully Field Selectable via the FOUNDATION

Fieldbus Interface

Lowest Limit................................................... 0.05% O

2

Highest Limit.................................................. 25.00% O

2

Accuracy.............................................................. ±1.5% of reading or 0.05% O

2

, whichever is greater

System Response to Calibration Check Gas...... Initial response in less than 3 seconds

T90 in less than 10 seconds

Probe

Lengths................................................................ 20 in. (508 mm)

26 in. (660 mm)

34.625 in. (880 mm)

Temperature Limits

Process Temperature Limits ......................... 550° to 1400°C (1022° to 2552°F)

Operation to 1600°C (2912°F) with reduced cell life.

Ambient ......................................................... -40° to 149°C (-40° to 300°F) Ambient

Mounting and Mounting Position......................... Vertical or Horizontal

Materials of Construction - Process Wetted Parts

Inner Probe ............................................. Zirconia

Outer Protection Tube............................. Alumina [1600°C (2912°F) limit]

Inconel 600 [1000°C (1832°F) limit]

Probe Junction Box................................. Cast aluminum

Speed of Installation/Withdrawal......................... 1 in. (25.4 mm) per minute

Hazardous Area Certification .............................. Intrinsically safe per EN50 014 (1977), clause 1.3

(1)

(pending)

Reference Air Requirement................................. 100 ml per minute (0.2 scfh) of clean, dry instrument air;

1/4 in. tube fittings

Calibration Check Gas Fittings............................ 1/4 in. tube fittings

Cabling ................................................................ Two twisted pairs, shielded

Electronics

Enclosure ............................................................ IP65 (NEMA 4X), weatherproof, and corrosion-resistant

Materials of Construction .................................... Low copper aluminum

Ambient Temperature Limits ............................... -20° to 65°C (-4° to 149°F)

Relative Humidity ................................................ 95% with covers sealed

Inputs (from O

2

Probe) ........................................ Two wires - O

2

signal, Two wires - type B thermocouple

Output ................................................................ FOUNDATION Fieldbus digital signal

Fieldbus Logic Function Blocks

Two AI Blocks: Execution Rate .................... 75mS

PID Block: Execution Rate ........................... 150mS

Fieldbus Segment Power Consumption ............. 30mA max, 30VDC max

Hazardous Area Certification .............................. Cenelec EEx ia IIC T4 or T5(2) (pending)

NEC Class I Div.I Group B,C,D (pending)

Fisher-Rosemount has satisfied all obligations coming from the

European legislation to harmonize the product requirements in Europe.

Power Transient Protection................................. IEC 801-4

Shipping Weight .................................................. 10 lbs (4.5 kg)

Infrared Remote Control

Power Requirements........................................... Three AAA batteries

Hazardous Area Certification .............................. Cenelec EEx ia IIC Class I, Div. I, Group A, B, C, D

(1)

Thermocouple and O

2

probe cell are both unpowered, developing a millivolt emf, and are considered a “simple ap-

paratus” by certifying agencies.

(2)

Dependent on ambient temperature limits.

Instruction Manual

IB-106-4081 Rev. 1.2

September, 2002

Rosemount Analytical Inc. A Division of Emerson Process Management Installation 2-1

Model 4081FG

SECTION 2

INSTALLATION

2-1 PRE-INSTALLATION

a. Inspect

Carefully inspect the shipping container for

any evidence of damage. If the container is

damaged, notify the carrier immediately.

b. Packing List

Confirm all items shown on the packing list

are present. Notify Rosemount Analytical

immediately if items are missing.

Before installing this equipment, read

the “Safety instructions for the wiring

and installation of this apparatus” at

the front of this Instruction Bulletin.

Failure to follow the safety instruc-

tions could result in serious injury or

death.

2-2 MECHANICAL INSTALLATION

Avoid installation locations near

steam soot blowers.

a. Locating Oxygen Probe

1. The location of the oxygen probe in the

stack or flue is important for maximum

accuracy in the oxygen analyzing proc-

ess. The probe must be positioned so

the gas it measures is representative of

the process. Best results are normally

obtained if the probe is positioned near

the center of the duct (40-60% insertion).

Longer ducts may require several ana-

lyzers since the O

2

can vary due to

stratification. A point too near the wall of

the duct, or the inside radius of a bend,

may not provide a representative sample

because of the very low flow conditions.

The sensing point should be selected so

the process gas temperature falls within

a range of 550° to 1600°C (1022° to

2912°F). Figure 2-1 provides mechani-

cal installation references.

2. Check the flue or stack for holes and

air leakage. The presence of this con-

dition will substantially affect the accu-

racy of the oxygen reading. Therefore,

either make the necessary repairs or

install the probe up-stream of any

leakage.

3. Ensure the area is clear of internal and

external obstructions that will interfere

with installation and maintenance ac-

cess to the probe. Allow adequate

clearance for probe removal (Figure

2-1).

b. Installing Oxygen Probe

The probe was specially packaged to

prevent breakage due to handling. Do

not remove the padding material from

the probe until immediately before in-

stallation.

1. Ensure all components are available to

install the probe.

NOTE

Leave the probe inner protective cover

in place until installation. This is re-

quired to protect the ceramic cell dur-

ing movement.

2. If using an optional adapter plate

(Figure 2-2) or an optional mounting

flange (Figure 2-3), weld or bolt the

component onto the duct. The through

hole in the stack or duct wall and re-

fractory material must be 2 in. (50.8

mm) diameter, minimum.

2

Instruction Manual

IB-106-4081 Rev. 1.2

September, 2002

2-2 Installation Rosemount Analytical Inc. A Division of Emerson Process Management

Model 4081FG

Figure 2-1. Probe Installation Details

29750002

PLATE DIMENSIONS

DIMENSION

ANSI

4512C34G01

DIN

4512C36G01

JIS

4512C35G01

“C” DIA. 4.75 (121) 5.71 (145) 5.12 (130)

“B” THREAD 0.625-11 M-16x2 M-12x1.75

“A” 6.00 (153) 7.5 (191) 6.50 (165)

METAL WALL

STACK OR DUCT

MASONRY WALL

STACK

3.00 SCHEDULE 40

PIPE SLEEVE

SUPPLIED BY CUSTOMER

WELD OR BOLT ADAPTER

PLATE TO STACK OR DUCT.

JOINT MUST BE AIR TIGHT.

WELD PIPE TO

ADAPTER PLATE

JOINT MUST

BE AIR TIGHT

B

C

A

NOTE: DIMENSIONS ARE

IN INCHES WITH

MILLIMETERS IN

PARENTHESES.

3.50 (89)

O.D. REF

2.50 (63.5)

MIN. DIA.

Figure 2-2. Optional Adapter Plate

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Rosemount 4081FG 2-Wire In Situ O2 Analyzer (550° to 1600°C) Owner's manual

Rosemount 4081FG 2-Wire In Situ O2 Analyzer (550° to 1600°C) Owner's manual

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